Vehicle Headlight Lens Curved Surfaces Bright-Dark Boundary
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Solution Overview
Problem
Existing vehicle headlight lenses face challenges in achieving cost-effective production with high optical quality and improving the imaging of bright-dark boundaries.
Innovation Solution
A headlight lens composed of a transparent material, moulded on both sides, featuring an optically active surface facing the light source that is convexly or concavely curved, with a lens rim that constitutes 1% to 8% of the lens volume, and a surface roughness of less than 0.1 μm, designed to enhance optical properties and imaging capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a headlight lens is moulded on both sides with curved optically active surfaces, then optical quality is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies curvature to the optically active surfaces of the headlight lens, with the first optically active surface being convexly or concavely curved and the second optically active surface being convexly curved. This curvature design improves optical quality by better directing light beams while maintaining manufacturability through standard moulding processes.
2Manufacturing precision
If a lens rim is added to the headlight lens, then imaging of bright-dark boundary is improved, but material usage and cost increase
Solution Approach 1:
The patent introduces a lens rim as a localized structural feature with specific imaging functionality. The lens rim is positioned at the edge of the first optically active surface and has a specific thickness (1-10 mm), creating a local optical effect that improves bright-dark boundary imaging without requiring the entire lens to be redesigned.
Solution Approach 2:
The patent specifies that the lens rim volume should amount to 1% to 8% of the total headlight lens volume. This parameter constraint optimizes the balance between imaging performance improvement and material consumption, ensuring the lens rim provides sufficient optical function while limiting excess material usage.
3Manufacturing precision
If surface roughness is reduced to less than 0.1 μm, then optical quality is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent specifies a surface roughness parameter of less than 0.1 μm for the optically active surfaces. This quantitative parameter control achieves high optical quality by minimizing light scattering while remaining compatible with precision moulding technologies, balancing manufacturing feasibility with optical performance requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a cost-effective vehicle headlight lens with improved optical quality and enhanced imaging of bright-dark boundaries, effectively addressing the existing challenges in the field.
Implementation Method 1
a headlight lens (2) for a vehicle headlight (1), in particular for a motor vehicle headlight (1), comprising a light source (10)
Data Source
AI summary
The invention relates to a headlight lens (2, 2B, 2C, 2D, 2E, 2F) for a vehicle headlight (1) comprising a light source (10), in particular for a motor vehicle headlight, the headlight lens (2, 2B, 2C, 2D, 2E, 2F) comprising a lens body (3, 3B, 3C, 3D, 3E, 3F) composed of a transparent material which is moulded (blank-pressed) on both sides and which comprises an optically active surface (5, 5B, 5C, 5D, 5E, 5F), that is to face the light source (10) and an optically active surface (4, 4B, 4C, 4D, 4E, 4F) that faces away from the light source (10), the optically active surface (4, 4B, 4C, 4D, 4E, 4F) that faces away from the light source (10) being convexly curved, the optically active surface (5, 5B, 5C, 5D, 5E, 5F) that is to face the light source (10) being curved, and the headlight lens (2, 2B, 2C, 2D, 2E, 2F) comprising a lens rim (6, 6B, 6C, 6D, 6E, 6F) externally on the optically active surface (5, 5B, 5C, 5D, 5E, 5F) that is to face the light source (10), the volume of which lens rim (6, 6B, 6C, 6D, 6E, 6F) amounts to 1% to 8% of the volume of the headlight lens (2, 2B, 2C, 2D, 2E, 2F).